Gas-fed fermentation reactors, systems and processes

Abstract

Reactors, systems and processes for the production of biomass by culturing microorganisms in aqueous liquid culture medium circulating inner loop reactor which utilize nonvertical pressure reduction zones are described. Recovery and processing of the culture microorganisms to obtain products, such as proteins or hydrocarbons is described.

The invention claimed is: 
     
       1. A process for stimulating production of biomass comprising:
 flowing through a loop section of a loop reactor, a multi-phase mixture of a gas and a liquid culture medium, the multi-phase mixture containing a biomass, the loop section including a portion sloped upward in the direction of flow of the multi-phase mixture in the loop section and an outlet; 
 introducing nutrients into the multi-phase mixture; 
 introducing a carbon-containing gas into the multi-phase mixture; 
 passing the multi-phase mixture of a gas and a liquid culture medium from the loop section of the loop reactor into a first non-vertical pressure reduction zone of the loop reactor, the first non-vertical pressure reduction zone of the loop reactor including an eccentric expander that includes an inner diameter that transitions from a first end having a first diameter to a second end having a second diameter larger than the first diameter and an edge extending between the first end and a beginning of the second end that is parallel to a portion of the loop section to which the first non-vertical pressure reduction zone is connected; 
 separating the multi-phase mixture of a gas and a liquid culture medium into a gas phase and a liquid phase in the first non-vertical pressure reduction zone; 
 flowing the gas phase and the liquid phase separated from the multi-phase mixture of a gas and a liquid culture medium into a gas/liquid separation vessel; and 
 removing the liquid phase from an outlet of the gas/liquid separation vessel and delivering the removed liquid phase to an inlet of the loop section. 
 
     
     
       2. The process of  claim 1 , wherein the passing the multi-phase mixture of a gas and a liquid culture medium into the first non-vertical pressure reduction zone of the loop reactor includes passing the multi-phase mixture of a gas and a liquid culture medium into a pipe section of the eccentric expander, the pipe section having a constant inner diameter. 
     
     
       3. The process of  claim 2 , wherein the passing the multi-phase mixture of a gas and a liquid culture medium into the first non-vertical pressure reduction zone of the loop reactor includes passing the multi-phase mixture of a gas and a liquid culture medium into an eccentric expander section of the eccentric expander. 
     
     
       4. The process of  claim 3 , wherein the first inner diameter is equal to the constant inner diameter of the pipe section. 
     
     
       5. The process of  claim 4 , further comprising passing the multi-phase mixture of a gas and a liquid culture medium through a control valve before passing the multi-phase mixture of a gas and a liquid culture medium into the pipe section. 
     
     
       6. The process of  claim 1 , further comprising introducing a desorption gas into a non-vertical portion of the loop section. 
     
     
       7. The process of  claim 1 , flowing the multi-phase mixture of a gas and a liquid culture medium from a control valve to the eccentric expander. 
     
     
       8. The process of  claim 1 , further comprising flowing the multi-phase mixture through a control valve before flowing the multi-phase mixture into the first pressure reduction zone including the eccentric expander. 
     
     
       9. The process of  claim 1 , further comprising flowing the multi-phase mixture of a gas and a liquid culture medium through an eccentric reducer prior to flowing the multi-phase mixture of a gas and a liquid culture medium into the eccentric expander. 
     
     
       10. A process for stimulating production of biomass comprising:
 flowing through a loop section of a loop reactor, a multi-phase mixture of a gas and a liquid culture medium, the multi-phase mixture containing a biomass, the loop section including an outlet; 
 introducing nutrients into the multi-phase mixture; 
 introducing a carbon-containing gas into the multi-phase mixture; 
 passing the multi-phase mixture of a gas and a liquid culture medium from the loop section of the loop reactor into a first non-vertical pressure reduction zone of the loop reactor, the first non-vertical pressure reduction zone of the loop reactor including an eccentric expander that includes an inner diameter that transitions from a first end having a first diameter to a second end having a second diameter larger than the first diameter and an edge extending between the first end and a beginning of the second end that is parallel to a portion of the loop section to which the first non-vertical pressure reduction zone is connected; 
 separating the multi-phase mixture of a gas and a liquid culture medium into a gas phase and a liquid phase in the first non-vertical pressure reduction zone; 
 flowing the gas phase and the liquid phase separated from the multi-phase mixture of a gas and a liquid culture medium into a gas/liquid separation vessel; and 
 removing the liquid phase from an outlet of the gas/liquid separation vessel and delivering the removed liquid phase to an inlet of the loop section. 
 
     
     
       11. The process of  claim 10 , wherein the eccentric expander includes a pipe section having a constant inner diameter. 
     
     
       12. The process of  claim 10 , wherein the loop section includes a portion sloped downward in the direction of flow of the multi-phase mixture in the loop section. 
     
     
       13. The process of  claim 12 , wherein the loop section includes a portion sloped upward in the direction of flow of the multi-phase mixture in the loop section. 
     
     
       14. The process of  claim 12 , wherein the eccentric expander includes an eccentric expander section and a pipe section. 
     
     
       15. The process of  claim 12 , wherein the eccentric expander has a first end having a first inner diameter and a second end having a second inner diameter, the second inner diameter being larger than the first inner diameter, and the first inner diameter equal to a constant inner diameter of a control valve. 
     
     
       16. The process of  claim 10 , further comprising flowing the multi-phase mixture of a gas and a liquid culture medium through an eccentric reducer prior to flowing the multi-phase mixture of a gas and a liquid culture medium into the eccentric expander. 
     
     
       17. The process of  claim 10 , further comprising flowing the multi-phase mixture of a gas and a liquid culture medium through a control valve before flowing the multi-phase mixture of a gas and a liquid culture medium into the eccentric expander. 
     
     
       18. The process of  claim 17 , further comprising flowing the multi-phase mixture of a gas and a liquid culture medium through an eccentric reducer before flowing the multi-phase mixture of a gas and a liquid culture medium into the control valve.